Beruflich Dokumente
Kultur Dokumente
Working group
21.01
February 2003
Page 1 of 29
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
219
February 2003
Cigré WG 21-01: Fredrik Rüter (SE, Convenor), Yuichi Maekawa (JP), Hajime Takehana (JP),
Steve Swingler (UK), Nigel Hampton (SE), Gunnar Evenset NO), Pierre Mirebeau (FR),
Ambrogio Orini (IT), Jean-Luc Parpal (CAN), Graham Lawson (US), and Matthias Kirchner (DE)
Copyright © 2002
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diffusion sur un réseau intranet ou un réseau d'entreprise.
Copyright © 2002
Ownership of a CIGRE publication, whether in paper form or on electronic support only
infers right of use for personal purposes..Are prohibited, except if explicity agreed by CIGRE,
total or partial reproduction of the publication for use other than personal and transfer to a
third party; hence circulation on any intranet or other company network is forbidden.
Page 2 of 29
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
TABLE OF CONTENTS
TABLE OF CONTENTS................................................................................................................ 2
1 INTRODUCTION.................................................................................................................... 4
1.1 Background........................................................................................................................ 4
1.2 Scope ................................................................................................................................. 4
1.3 Summary of Tests.............................................................................................................. 5
1.4 Definitions ......................................................................................................................... 5
1.4.1 Definitions - General....................................................................................................... 5
1.4.2 Definitions - Test Objects ............................................................................................... 6
1.4.3 Definitions - Test Voltages ............................................................................................. 7
1.4.4 Definitions – Thermal Cable Design Parameters............................................................ 8
1.4.5 Definitions – Thermal Conditions for Tests.................................................................... 9
1.4.6 Definitions – Conditions for Tests .................................................................................. 9
1.5 Range of Approval........................................................................................................... 10
1.5.1 Prequalification Test ................................................................................................. 10
1.5.2 Type Test .................................................................................................................. 10
2 DEVELOPMENT TESTS...................................................................................................... 11
3 PREQUALIFICATION TESTS............................................................................................. 12
3.1 Test Objects ..................................................................................................................... 12
3.2 Sequence of Tests ............................................................................................................ 12
3.3 Success Criteria, Re-testing and Interruptions ................................................................ 13
4 TYPE TESTS ......................................................................................................................... 13
4.1 Test Objects ..................................................................................................................... 13
4.2 Non-electrical Type Tests................................................................................................ 14
4.3 Electrical Type Test......................................................................................................... 14
4.3.1 Mechanical Pre-conditioning before Electrical Type Test............................................ 16
4.3.2 Load Cycle Test ............................................................................................................ 16
4.3.2.1 General - Load Cycle Test ...................................................................................... 16
4.3.2.2 Load Cycle Test - Cable System to be qualified for LCC Operation ..................... 16
4.3.2.3 Load Cycle Test - Cable System to be qualified for VSC Operation ..................... 16
4.3.3 Superimposed Impulse and Surge Voltage Test ........................................................... 17
4.3.3.1 General - Superimposed Impulse Voltage Test ...................................................... 17
4.3.3.2 Switching Surge Withstand Test - Cable System to be qualified for LCC Operation
............................................................................................................................................. 17
4.3.3.3 Switching Surge Withstand Test - Cable System to be qualified for VSC Operation
............................................................................................................................................. 17
4.3.3.4 Lightning Impulse Withstand Test.......................................................................... 17
4.3.3.5 Subsequent DC Test................................................................................................ 17
4.3.4 Success Criteria, Re-testing and Interruptions .............................................................. 18
4.4 Return Cable - Type Test................................................................................................. 18
4.4.1 General...................................................................................................................... 18
4.4.2 Mechanical Preconditioning ..................................................................................... 18
4.4.3 Thermomechanical Preconditioning ......................................................................... 18
4.4.4 AC Voltage Test ....................................................................................................... 19
4.4.5 Lightning Impulse Withstand Test............................................................................ 19
4.4.6 Cable Design with Integrated Return Conductor...................................................... 19
5 ROUTINE TESTS.................................................................................................................. 20
5.1 Transmission Cables........................................................................................................ 20
5.2 Return Cables or Conductors........................................................................................... 20
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
1 INTRODUCTION
1.1 Background
The potential of polyethylene-insulated cables for DC submarine high voltage applications was
recognised and studied in the 1950s following the successful implementation of thousands of
kilometres of polyethylene submarine communication cables. Experimental polyethylene DC
cables were produced in the 1960s for operation at 200 kV to ground.
The commercial application of extruded DC cables was hampered by a tendency for the cables to
fail during polarity reversal tests. This was generally attributed to the presence of space charges
trapped within the cable insulation.
In the 1990s, the development of new insulating materials and novel converter stations resulted
in renewed commercial interest in extruded DC cable for both submarine and land applications.
As increasing use of this emerging technology is foreseen, there is need for a common approach
to cable qualification and routine testing.
At the time of preparing this document there is laboratory experience at voltages up to and
including 500 kV, but operating experience is still limited to a few projects at 80 kV and recently
two commissioned systems at 150 kV. However, it is the opinion of WG 21-01 that within a few
years HVDC extruded cable systems will be in operation at voltages up to and including 250 kV.
The present document has, therefore, been developed for DC power transmission cable systems
up to 250 kV. The possibility of extending this range to higher voltage levels should be
examined when sufficient service and testing experience at the lower voltage levels has been
accumulated.
There are established CIGRÉ recommendations for paper lapped HVDC cables and long
extruded AC cables. There are IEC and other standards for extruded AC cables for land use. A
number of specific features prevents them from being applied to extruded DC cable systems and
hence, in 1999, CIGRÉ Study Committee 21 established a Working Group to develop test
recommendations for testing extruded DC cable systems.
The philosophy adopted has been that the tests recommended should apply to the complete
HVDC cable system as installed and as intended to function. Wherever possible, the tests have
been based on existing recommendations, standards and practices. New tests have, however,
been introduced where required by considerations specific to the new technology. It has also
been recognised that the new technology may involve the use of many different materials such as
thermoplastic or cross-linked polymers (either filled or unfilled) and differing manufacturing
processes. In consequence, the tests recommended are largely functional and not specific to one
material or manufacturing process.
1.2 Scope
This document recommends a series of tests on extruded cables for DC power transmission
systems (land or submarine cables and their accessories in fixed installations) up to and including
250 kV. Within the scope of these recommendations “extruded” shall mean either filled (e.g.
with mineral or carbon) or unfilled and either thermoplastic (e.g. Polyethylene [PE], etc) or
thermoset (e.g. crosslinked polyethylene [XLPE], Ethylene Propylene Rubber [EPR], etc)
insulations.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Development Tests Tests made during the development of the cable system
Prequalification Test Test made before supplying on a general commercial basis a type of
cable system covered by this recommendation in order to
demonstrate satisfactory long-term performance of the complete
cable system.
Type Tests Tests made on cables and accessories before supplying on a general
commercial basis a type of cable system covered by this
recommendation to verify the properties of a cable system prior to
supplying that particular system.
Tests after Installation Tests made on the completed cable system after installation and
prior to use to demonstrate system integrity.
1.4 Definitions
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
• VSC, Voltage source converter is (for the purpose of this document) a converter that
does not have the ability to change the voltage polarity of the cable system.
• An extrusion length is the length of cable conductor with the insulation and semi-
conductive layers as continuously extruded in the same non-interrupted extrusion
operation (excluding possible scrapped sections cut off from the starting and ending
sections).
• A manufacturing length is a whole extrusion length (or parts thereof if cut), where
construction elements (outside the outer semi-conducting layer) have been applied.
• A delivery length is defined as the shipping length of completed cable, possibly
including factory installed accessories. A delivery length may encompass one or more
jointed manufacturing lengths (or parts of manufacturing lengths), as would be typical
for a submarine cable. A typical delivery length for a land cable would be the
completed cable length on the cable drum.
• A factory joint is a joint between extrusion lengths / manufacturing lengths
manufactured under controlled factory conditions.
• A repair joint is a joint between two cables that are completed with all construction
elements.
• A field joint, is a joint between two cables that are completed with all construction
elements and in a state as installed in the field in the actual cable system.
• A transition joint, is a joint between two extruded cables of different designs. (A
transition joint may be further classified as a factory, a repair or a field joint).
Min 5 m cable
Test object Cable . Min 10 m.
Test object
between accessory Test object
Joint
Test objects Joint
Min 5 m cable
between accessory
Test objects
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
• U0 is the rated DC voltage between conductor and core screen for which the cable
system is designed.
• UT is the voltage during the type test and routine test. For the scope of this
recommendation UT = 1.85xU0.
• UTP1 is the voltage during the prequalification test (load cycle test), type test (polarity
reversal test) and test after installation. For the scope of this recommendation UTP1 =
1.45xU0.
• UTP2 is the voltage during the prequalification polarity reversal test. For the scope of
this recommendation UTP2 = 1.25xU0.
• UP1 is 1.15 x the maximum absolute peak value (Figure 2) of the lightning impulse
voltage, which the cable system can experience when the impulse has the opposite
polarity to the actual DC voltage.
• UP2,S is 1.15 x the maximum absolute peak value (Figure 2) of the switching surge
voltage, which the cable system can experience when the surge has the same polarity as
the actual DC voltage.
• UP2,O is 1.15 x the maximum absolute peak value (Figure 2) of the switching surge
voltage which the cable system can experience when the surge has the opposite
polarity as the actual DC voltage
• URC,AC is the maximum voltage a return cable can be subjected to due to temporary
damped alternating overvoltage. This voltage is typically induced by a commutation
failure, and the value should be supported by the supplier’s system calculations of the
HVDC link. The nature of the overvoltage is depending upon the configuration of the
HVDC link and needs to be calculated for each case.
• URC,DC is the max DC voltage in normal operation of the return cable.
Note
All voltages shall be applied without substantial interruption.
The ripple content of the DC test voltages shall not be greater than 3 percent.
Calibration shall be according to [1]
The basis for the selection of test factors is described in Appendix A.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
kV25 kV25
20
Up2,S 20
15 15 Up2,O
U
10
0 10
5 5
0 0
-5 -5
-10 -U
-10
0
-15 -15
-20 -20
-25 -25
time time
Figure 2: Schematic representations of the impulse test voltages. (Due to the constraints within
the DC system design UP2,S does not necessarily equal UP2,O, i.e. the same-polarity surge is
limited by surge arresters, but the opposite-polarity surge may be limited by the converter.)
• Tcond,max is the maximum temperature at which the cable conductor is designed to operate.
This value is to be stated by the supplier.
• ∆Tmax is the maximum temperature difference over the cable insulation (not including
semiconductive layers) at which the cable is designed to operate. This value is to be calculated
and stated by the supplier, who shall also provide evidence of the correlation between this
design value and data measured during testing.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
• The heating method used shall be conductor heating. The heating may be provided by either
DC or AC current, possibly in combination with external thermal insulation or cooling. The
actual ∆T and Tcond during testing need to be demonstrated.
• Load Cycles
Load cycles consist of both a heating period and a cooling period.
24 hour load cycles (for prequalification and type tests) consist of an 8 hour heating period
and a 16 hour cooling period. During the last 2 hours of heating, the conductor temperature
shall be ≥ Tcond,max and a temperature drop across the insulation ≥ ∆Tmax shall be maintained.
48 hour load cycles (for type test only) consist of a 24 hour heating period and a 24 hour
cooling period. During the last 18 hours of heating a conductor temperature ≥ Tcond,max and a
temperature drop across the insulation ≥ ∆Tmax shall be maintained. 48 hour load cycles are
only required as part of the type test procedure to ensure that electrical stress inversion is
well advanced within the cycle.
• High Load
High Load consists of a continuous heating period.
Within the first 8 hours of the heating period conductor temperature ≥ Tcond,max and
temperature drop across the insulation ≥ ∆Tmax shall be achieved and maintained for the rest
of the High Load test.
• Zero Load
No heating is applied.
• Impulse Test (superimposed impulse, switching, lightning)
Conductor temperature ≥ Tcond,max and temperature drop across the insulation ≥ ∆Tmax shall
be reached for a minimum 10 hours before voltage impulses are applied and shall be
maintained throughout the duration of the test .
Unless otherwise specified in the details for the particular test, tests shall be carried out at an
ambient temperature of (20 ± 15) ° C.
The temperature and voltage conditions are defined in sections 1.4.5 and 1.4.3 respectively.
Starting with positive voltage, the voltage polarity shall be reversed every 8 hours and one
reversal shall coincide with the cessation of loading current in every 24 hour loading cycle.
The recommended time duration for a polarity reversal is 2 minutes.
Prior to the first impulse of each test the test object shall be heated so that the temperature
conditions as defined in section 1.4.5 are achieved for at least 10 hours and the test object shall
have been subjected to U0 (of the relevant polarity) for at least 10 hours. These conditions have
been selected to reflect the electrical dynamics present within extruded insulations used for
HVDC.
Superimposed lightning impulse voltage shall be applied according to the procedure given in [2].
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
If the impulse test is not strictly practicable due to sample length and set up limitations, it is
recommended that the waveform be altered while remaining as close as possible to the
standardized risetime and decay time. If modification of the waveform does not prove effective,
the manufacturer may, at his discretion, shorten the installation provided that the length of cable
between the ends of adjacent accessories is at least 5m.
The cable samples shall withstand without failure 10 positive and 10 negative voltage impulses
at the voltage level UP1.
A lightning impulse test (Appendix C) can be selected as an alternative to the superimposed
lightning impulse test provided that the Bahder coefficient has been established for the actual
cable under test. The impulse voltage (from Appendix C) shall be applied according to the
procedure given in [3].
The prequalification test qualifies the manufacturer as a supplier of cable systems with the same
or lower voltage rating, the same or lower maximum conductor temperature and the same or
lower calculated maximum electrical stress at operating conditions. A cable system prequalified
according to these recommendations for LCC is also prequalified for VSC. A cable system
prequalified according to these recommendations for VSC is not also prequalified for LCC.
1.5.2 Type Test
The type approval shall be accepted as valid for cable systems within the scope of this
recommendation if the following conditions are met:
1. the actual designs, manufacturing processes and service conditions for the cable system are in
all essential aspects equal
2. service U0, UP1, UP2,S & UP2,O are equal or less
3. the mechanical stresses to be applied during pre-conditioning are equal or less than those of
the system already tested
4. service Tcond,max is equal or less than those tested
5. the actual conductor cross section is equal to a previous test, or within the range of previous
tests of cables with different cross-sections
6. the calculated maximum electrical stresses, under all operational conditions at the conductor
and the insulation screens, in the main insulation parts of the accessory and its boundaries are
equal to or lower than for the tested cable and accessory
7. a cable system qualified according to this recommendation for use with LCC is also qualified
for use with VSC, but not the opposite.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Irrespective of the above, the non-electrical type tests shall be judged on the basis of equal, in all
essential aspects, including the materials, manufacturing processes and relevant design elements
used.
2 DEVELOPMENT TESTS
The manufacturer should complete all analyses and development testing prior to commencing the
prequalification test. The precise nature and extent of development work and analyses shall be
left to the discretion of the manufacturer but may include the following:
• An evaluation of the materials and processes employed. Such evaluations would normally
include electrical resistivity assessments, breakdown tests and space charge measurements.
• An analysis of the electric stress distribution within the cable system insulation for a range of
typical installation and loading conditions.
• An assessment of the longterm stability, possibly involving factory experiments to assess the
ageing effects of various parameters, e.g. electrical stress, temperature, environmental
conditions etc.
• An assessment of the sensitivity of the electric stress distribution to the expected variations in
cable dimensions, material composition and process conditions (extrusion, post extrusion
treatments and finishing).
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
3 PREQUALIFICATION TESTS
Approximately 100m of cable including complete accessories (at least one of each type) with a
dielectric design suitable for practical applications shall be tested. Where appropriate mechanical
preconditioning may be considered before starting the prequalification test.
General:
1. Minimum duration is 360 days.
2. Conductor temperature and temperature difference across the insulation shall both be
controlled to the design level. Design levels in accessories and adjacent cables may
differ.
Note: The main objective of the prequalification test is to satisfactorily demonstrate the
insulation integrity during long times under DC, given the long dielectric time constants as
compared to AC. It is however recognized that other aspects of a specific installation may be
important, such as the thermo-mechanical effects due to the installation conditions. The
representation of specific installation conditions in the test set-up should be considered.
The sequence of tests for LCC and VSC are shown in the tables below
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
The length and sequence of the thermal conditions were selected with regard to the particular
electrical effects that can occur in extruded insulations when operated under HVDC. The
technical basis for the test durations is given in Appendix A.
A minimum rest period without voltage but with heating of 24 hours is recommended between
the high load tests at different polarities.
The manufacturer may, at his discretion, conduct tests and / or examinations after completion of
the prequalification test for engineering information only.
The criterion for a successful outcome to the prequalification test is that all tests shall have been
performed without breakdown of that test object.
If there is a breakdown in a test object the complete prequalification test shall be repeated for
that particular test object.
After any interruption, for example an interruption caused by external factors (loss of power,
irregular external flashover of terminations etc) the test may be resumed. The actual load cycle,
surge or impulse during which the interruption occurred, shall be repeated. If the interruption
occurs during a constant load period the day the interruption occurred shall be repeated.
4 TYPE TESTS
All components of the cable system (cable and accessories) shall be subjected to type testing. It
is acceptable to test different parts of a system in different test loops. However these test loops
must cover all relevant cable system components.
All test objects offered for type testing, shall have successfully completed routine testing prior to
being subjected to type testing.
By definition, an accessory includes 0.5 m of cable on each side (Figure 1), measured from the
point on the cable where no disassembling or dismantling for the purpose of installation of
accessory has taken place.
The non-interrupted cable length between accessories (Figure 1) in a test loop shall be a
minimum of 5 m.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Where the actual cable insulation thickness deviates from the stated nominal thickness, the
procedure specified in [4] shall apply.
Any non-continuous design feature (such as a metallic connection between metallic layers) shall
be included in the cable test object.
Test objects for land or submarine application shall be subjected to the appropriate mechanical
pre-conditioning.
Test objects for the electrical and non-electrical type tests must not be the same physical samples
unless required by the recommendation for the non-electrical test.
The cable system shall be subjected to the applicable non-electrical type testing as specified in
[4].
Cable joints intended for burial on land shall be subjected to the Outer Protection Test specified
in [4].
Cable systems intended for installation on land where water blocking is included shall be
subjected to a water penetration test as specified in [4].
Cable systems intended to be installed as submarine cables shall be subjected to water integrity
testing as specified in [5]. This test would also qualify the cable for installation on land.
Cables with metallic earthing connections through plastic sheaths shall be subjected to
the test in [2].
Cable systems employing longitudinally applied metallic foils may, where appropriate, be
subjected to the tests in [6].The WG recognises that there may be certain DC designs (for
example small cables, armoured cables etc) where the precise details of guidelines will
not be applicable.
The principal overview of the electrical type tests is described in Figure 3 below.
Page 15 of 29
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Land Cables
Submarine Cables
Bend Test IEC
Tensile Bend Test
60840 [4]
Electra 171 [7]
DC
(clause 4.3.3.5)
Figure 3: Schematic representation of the sequence of tests for Land and Submarine Cables
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
The intent of the mechanical pre-conditioning is to subject the test objects to the maximum
mechanical stress that the cable system will experience during handling, installation and
recovery. Consequently the factory joints and flexible repair joints for submarine cables shall be
included, but field joints for land-cables are not to be included.
The load cycle test shall be performed on test objects that have been subjected to the appropriate
mechanical pre-conditioning. Accessories in the cable system that are not relevant for
mechanical pre-conditioning, are to be installed as test objects together with the pre-conditioned
test objects.
If the test loop consists of cables with different designs connected with a transition joint, then
each cable design is qualified to the relevant thermal conditions (Tcond,max and ∆T) and the
transition joint is qualified to the higher temperature.
(Note: this means that cable on one side of the transition joint under test, may not have been
qualified in this test to its maximum temperature in the scheme).
4.3.2.2 Load Cycle Test - Cable System to be qualified for LCC Operation
A rest period without voltage but with heating is permitted between test blocks. A minimum rest
period of 24 hours is recommended.
Positive polarity was selected for the 48 hour load cycles as this is believed to be the most
onerous condition for accessories.
4.3.2.3 Load Cycle Test - Cable System to be qualified for VSC Operation
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
A rest period without voltage but with heating is permitted between test blocks. A minimum rest
period of 24 hours is recommended.
Positive polarity was selected for the 48 hour load cycles as this is believed to be the most
onerous condition for accessories.
The thermal conditions for the tests are described in Section 1.4.5.
The superimposed impulse voltage test is to be performed on test objects that have successfully
passed the load cycle test.
4.3.3.2 Switching Surge Withstand Test - Cable System to be qualified for LCC
Operation
4.3.3.3 Switching Surge Withstand Test - Cable System to be qualified for VSC
Operation
If the intended installation of the cable system is such that it is not exposed to lightning strikes
(direct or indirect), these tests need not be done.
After the successful completion of the surge and impulse testing as above, the test object shall be
subjected to 2 hours at a negative DC voltage of UT, no heating.
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
The criterion for a successful outcome to the type test is that that all tests have been performed
without breakdown of that test object and that all other non electrical requirements have been
complied with.
In case of interruptions / deviations in test parameters during load cycles / polarity reversal test
or superimposed impulse voltage test, the test in question shall be repeated.
In case of a breakdown of insulation, when testing several objects simultaneously, the faulty
object may be removed and the incident treated as an interruption. The faulty object is
considered to have failed the test requirements. Any fault within any extension (0.5m) to a test
object, for example an accessory, is considered to be associated with that test object only.
In the case of an irregular external flashover of end terminations the flashover shall be treated as
an interruption. Irregular flashover is usually related to unusual dust conditions or objects close
to the termination.
4.4.1 General
Return Cables are grounded at one end and are subjected to a DC voltage determined by the
cable resistance and the current at the other end of the link. System calculations, taking into
account the different fault scenarios, should be performed by the supplier to determine the
relevant temporary overvoltages in the power frequency domain for the Return Cable for the
actual link. In particular, temporary overvoltages caused by commutation failure may be the
criteria for dimensioning of the return cable insulation and accessories. To verify that the cable
system can withstand overvoltages caused by commutation failure an AC voltage test at power
frequency test shall be performed.
If different designs (different insulation thicknesses) are used along the return path, each design
needs to be considered individually.
Return cables may be protected by surge arresters, in which case this feature needs to be taken
into consideration in the system studies and consequently in determining URC,AC.
The Return Cable test object shall be subjected to mechanical preconditioning acc. to clause
4.3.1, as applicable.
After mechanical preconditioning, the Return Cable test object shall be subjected to
thermomechanical preconditioning, consisting of 24 daily load cycles. During the execution of
this preconditioning the relevant thermal properties for the return cable shall be fulfilled
according to the principles stipulated in clause 4.3.2.1. No voltage needs to be applied.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
After the mechanical and thermomechanical preconditioning, the Return Cable test object shall
be subjected to a no load AC test at a power frequency voltage of 1.15 x URC,AC at ambient
temperature. The voltage shall be applied for 30 minutes.
If applicable, the Return Cable test object shall be subjected to a lightning impulse withstand test
with the relevant test voltages and according to the principles given in clause 4.3.3.4.
If the Transmission Cable is such that the return path is integrated, the return path function
should be tested together with the Transmission Cable in an integrated test program.
Page 20 of 29
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
5 ROUTINE TESTS
Routine tests (which include what is in some other documents referred to as the Factory
Acceptance Test) are made to demonstrate the integrity of the delivery lengths.
Every delivery length of cable shall be submitted to a negative DC voltage equal to the test
voltage defined for the load cycle test UT and applied between conductor and sheath for 15
minutes.
The experience of using DC voltage for routine testing of extruded DC cables is limited. It is the
opinion of the Working Group that in addition to the DC test, testing with AC voltage could be
considered provided that the insulation system and the cable design allows AC testing. Long
manufacturing lengths and high voltage levels may render AC testing impractical. In the event
that AC testing is employed, the voltage level, frequency (power or other frequencies) and time
of application shall be agreed between the manufacturer and purchaser.
If required for the particular contract or order, the oversheath may be subjected to the routine
electrical test specified in [8].
Every delivery length of cable shall be submitted to a voltage test applied between conductor and
sheath.
AC testing is to be preferred for the testing of Return Conductors, the voltage level and time of
application shall be agreed between the manufacturer and purchaser. Long manufacturing lengths
and high voltage levels may however render AC testing impractical; in this case a suitable DC
voltage, agreed between manufacturer and customer, shall be applied. It is recommended that the
DC test voltage be no lower than the highest of either 2.5 x URC,DC, or 25 kV; the voltage shall be
applied between conductor and sheath for 15 minutes.
6 SAMPLE TESTS
For the tests in this section, refer to the respective IEC specification for AC extruded power
cables [4].
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
6.7 Hot Set Test for XLPE and EPR Insulation (where applicable)
The installed HV cable system shall be submitted to a negative polarity DC voltage of UTP1. The
test duration shall be 15 min.
The installed return cable system shall be submitted to a negative polarity DC voltage that has
been agreed between the manufacturer and the customer. The test duration shall be 15 min.
For underground cables electrical testing of the outer sheath subsequent to laying should be
considered. If appropriate the test shall be performed according to [8].
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
8 REFERENCES
[4] Power cables with extruded insulation and their accessories IEC 60840
for rated voltages above 30 kV (Um=36 kV) up to 150 kV
(Um=170 kV) - Test methods and requirements
[6] Guidelines for tests on High Voltage cables with extruded Electra 141
insulation and laminated protective coverings
[8] Tests on cable oversheaths which have a special protective IEC 60229
function and are applied by extrusion
[12] B.Aladenize & al, Field distribution in HVDC cables: JICABLE 99, paper B7.8
dependence on insulating materials
[13] Power cables with extruded insulation and their accessories IEC 62067
for rated voltages above 150 kV (Um=170 kV) up to 500
kV (Um=550 kV) - Test methods and requirements
Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
9. APPENDICES
DC VOLTAGE FACTORS
The multiplication factors for the test voltages and periods have been determined based on
consideration of the available Voltage-time (V-t) characteristics. The precise nature of the V-t
characteristic has not been determined for DC operation. However the Working Group was of
the opinion that the Inverse Power Law model provided a conservative basis for the work. The
precise details of the approach are shown below,
V n ⋅ t = const.
where
V : voltage
t : time
n : life exponent from V − t characteristic
test volatge Vdc is;
Vdc = V0 × K1
where
V0 : system voltage
K1 : deterioration coefficient
K1 = n t 0 / t 1
where
t 0 : design life (40years)
t1 : test duration
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Using the approach described above it is possible to determine the test voltage factors that are
equivalent to a prescribed system life when testing for a shorter time. In this work the WG has
used a system life of 40 years. The approach requires knowledge of the ageing parameter “n”
which is determined empirically from endurance tests on cables. The knowledge of “n” under
DC was not sufficient for the WG to identify a precise value. However they were able to estimate
a lower limit (n = 10) which was used to determine the test voltage factor.
Prequalification Type
Test Test
Design Life - t0 (years) 40 40
On this basis the WG identified the test factor of 1.45 as equivalent to approximately 40 years
operation at rated voltage when applied for 1 year and the test factor of 1.85 when applied for 30
days
IMPULSE
In the light of the good experience which has resulted from the use of the previous Electra
recommendations within [9] [10] [2] it was decided that the same approach to selection of test
factors would be applied.
POLARITY REVERSAL
The approach for test factors is based on the principle of applying the same additional voltage for
the polarity reversal as that applied for the constant voltage test . This approach has been used in
previous DC recommendations. The table sets out previous practice relating the polarity reversal
tests and the used test factors.
For example: At a polarity reversal in real operation, the cable system experiences a voltage step
of 2U0. Applying a test factor of 1.45 in a polarity reversal test gives that the cable system under
test experiences a voltage step of 2 . 1.45 U0 = 2.9U0, i.e. 0.9U0 more than in real operation.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
The experience with using DC voltage for routine testing of extruded DC cables is limited.
However there is evidence from the use of DC voltages as an installation test for AC cables to
indicate that it may not be sufficiently searching. It is the opinion of the Working Group that for
routine tests, in addition to the DC test, testing with AC voltage should be recommended but not
required.
When considering the potential use of AC the Working Group recognizes that there may be
circumstances that render AC testing impossible or impractical, such as a cable insulation that is
not suitable for AC stressing or long manufacturing lengths. This is to be agreed upon on
individual basis between the supplier and the purchaser. It is also necessary to agree on the exact
performance of the test (test time, test voltage, frequency).
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
The field distribution within a DC power cable in operation differs from the Laplace field (∝ 1/r)
due to the fact that the conductivity of the insulation depends on its temperature (which
decreases from the conductor to the sheath) and the local electric field. These phenomena
generate a divergence, which is in addition to that derived from the cable geometry.
Calculations show that a time equivalent to 10 τ has to pass to approach the steady state
distribution of the divergence. The table gives the range of times to stability (10 τ) as a function
of temperature for different materials that are likely to be used for DC extruded cables.
Practically this means that the time to achieve a stable electrical stress distribution will depend
upon temperature. Thus it is important to select test times that permit probable insulation systems
to reach a stable electrical stress distribution. These considerations provide the foundations for
the times of the Zero Load, High Load and 48 hour Load Cycle Tests.
Injection of charges from the electrodes also operates, however the 10 τ time constant covers the
time needed for these injection processes.
In addition, considering the actual usage of HVDC links, the experimentation constraints and the
total time of the tests the WG adopted the following testing times. The WG judged that they
would “test” the performance of the proposed HVDC insulation systems in a practical
manner[11], [12]:
(Days) (Days)
Zero load ≈20°C 120 min 2.3< 10 τ < 180
(Pre qualification)
48 Hour Load Cycle: 60°C to 90°C 1 0.003< 10 τ < 1.8
(Type Approval) (manufacturer design) heating period
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
The development of the detailed technical test schemes described in Section 3.2 has been guided
by the following principles
1. Minimum duration is 360 days
2. Conductor temperature and temperature difference across the insulation, for part of the test
loop, shall both be controlled to the design level within the loading portions of the test
3. The tests shall commence with a minimum of 60 days of 24 hours load cycles at UTP1 for
thermo-mechanical conditioning
4. There shall be, in total, a minimum of 120 days of load cycles; for LCC, a minimum of 80
days shall be at UTP1 and a minimum of 40 days of polarity reversals at UTP2
5. There shall be a minimum of 30 consecutive days under constant high load (see section
1.4.5) at positive polarity UTP1
6. There shall be a minimum of 30 consecutive days under constant high load (see section
1.4.5) at negative polarity UTP1
7. There shall be a minimum of 120 consecutive days with zero load (see section 1.4.5) at
negative polarity UTP1
8. The test shall be completed with a superimposed lightning impulse test (see section 1.4.5).
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
Equivalent lightning impulse test may be selected as an alternative to the superimposed lightning
impulse test (prequalification and type test) by allowing for the effect of any space charge
accumulation in the insulation. The voltage used for the equivalent lightning impulse is higher
than that used for the superimposed lightning impulse because it must allow for the space charge
distortion of the electrical field which may cause a higher electrical field in the insulation. In
order to estimate the distortion by space charge, Bahder’s Coefficient (K) should be used.
Bahder’s Coefficient depends on both the insulation material of the cable system and the cable
system design. Bahder’s Coefficient is defined by following equation.
The voltage of equivalent lightning impulse test can be calculated by using Bahder’s Coefficient
as follows.
Vimp = (Vp M + V0 K)
Where,
Vimp : equivalent lightning impulse voltage
Vp : arrester protection level
V0 : system voltage
The temperature conditions for the test are defined in section 1.4.5.
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Recommendations for testing DC extruded cable systems for power transmission at a rated voltage up to 250 kV
APPENDIX D COMPARISON WITH GUIDELINES AND RECOMMENDATIONS FOR TRANSMISSION CABLE TESTS
Recommendations for Testing of Rec. for Electrical Tests
Cables with Extruded Long AC Submarine Cables with Prequalification and
Recommendations for Testing Recommendations for Tests
Insulation and Their Extruded Insulation for System Development on
DC Extruded Cable System for of Power Transmission DC
Accessories for Rated Voltage above 30 to 150kV, [5] Extruded Cables and
Power Transmission at a rated Cables for A Rated Voltage
Voltages above 150kV up to Accessories at Voltages
voltage up to 250 kV up to 800kV, [2]
500kV, [13] >150kV and <400kV,
[14]
CIGRE Electra 151, 1993
WG21-01 CIGRE Electra 189, 2000 IEC 62067 CIGRE Electra 189, 2000
AC400kV, Extruded Cable,
DC Extruded Cable, up to 250kV DC800kV, Paper-insulated Cable AC500kV, Extruded Cable AC150kV, Extruded Submarine Cable
PQ
Evaluation of material and
processes
Development Tests shall be at the discretion of the
Evaluation of Weibull
Test manufacturer.
parameters
Determination of “n”
100m including accessories
360days, 1.45U0 Load cycle Test
Long term AC test with heat
Different procedures for LCC & VSC : 1.7U0, 1year
Prequalification : 180 heating cycles
cycles
Load Cycle Test (min 120)
Test Impulse test
High Load Test Lightning impulse voltage test
AC test
Zero Load Test : 10positive, 10negative
Superimposed LI Test
Non-electrical Test Water penetration test
Mechanical Pre-conditioning Load cycle test Bending test Conductor penetration
30 days : +1.8U0x10,-1.8U0x10 Partial discharge test Outer sheath penetration
1.85U0 Polarity reversal test (after LC) Tanδ measurement Partial discharge test
Type Test Different procedures for LCC & VSC : 1.4U0x60, every 4h, 10 l.c. Load Cycle Test Loss angle measurement
Load Cycle Test Superimposed impulse test Switching impulse voltage test Load cycle test
Superimposed Lightning Impulse Test :-U0+1.15Imp, U0-1.15Imp Partial discharge test
Subsequent DC Test Ligthning Impulse test
High-voltage test On manufacturing length
: 1.8U0, 15min. High voltage test
Delivery Length Conductor resistance test Partial discharge test Partial discharge test on factory installed
Routine Test DC Test Capacitance test Voltage test joints
: -1.85U0x15min Power factor test Electrical test on oversheath Factory acceptance
Factory acceptance test High voltage test
: 1.8U0, 15min. TDR
Sample Test according to IEC 60840
High Voltage Test : -1.45 U0x15min AC voltage test
After Test on Polymeric Sheaths DC voltage test DC voltage test (oversheath) : 1.7U0, 90min.
Installation Test : according to IEC 60229 : 1.4U0, 15min. AC voltage test (insulation) : 1.0U0, 24hours
TDR for information